External PCB Bridge Contact for Compact 3D LED Wiring
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Solution Overview
Problem
The challenge in automotive lighting applications is to electrically couple LED strings to a vehicle's electrical system while maintaining compactness and avoiding damage to the LED housing, especially in 3D LEDs with space constraints and potential soldering risks.
Innovation Solution
A 3D LED electrical contact system comprising a PCB bridge and connector that extends beyond the LED housing, allowing secure electrical coupling via a PCB bridge soldered to an end interposer and a connector that avoids damaging the housing, using castellations for easy soldering and accommodating terminal pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical contacts are integrated within the silicone housing, then compactness is improved, but the risk of burning or melting the housing increases
Solution Approach 1:
The electrical contact is extracted from the silicone housing interior and positioned externally. The PCB bridge extends beyond the housing to provide electrical coupling, while the PCB connector is positioned outside the housing to connect with external wires. This separation removes the heat-generating electrical contact from the heat-sensitive silicone housing, eliminating the burning or melting risk while maintaining compact overall design.
Solution Approach 2:
The PCB bridge serves as an intermediary component that bridges the gap between the LED interposer inside the housing and the external electrical connector. It extends the electrical connection path outward, allowing electrical coupling to occur outside the housing boundary, thus protecting the housing from thermal damage while maintaining electrical functionality.
2Area of stationary object
If electrical contacts are placed within the housing, then space utilization is improved, but obstruction of the optical path occurs
Solution Approach 1:
The electrical contact components (PCB bridge and PCB connector) are extracted from the housing interior space and positioned externally. This removes them from the optical path region, eliminating obstruction of light emission from the LEDs while still providing efficient electrical coupling to the LED interposer through the extended PCB bridge structure.
3Device complexity
If electrical wires are directly connected to LEDs, then connection simplicity is improved, but mechanical flexibility is reduced
Solution Approach 1:
The electrical connection system is segmented into distinct functional modules: the LED interposer, the PCB bridge, and the PCB connector. This modular segmentation allows each component to be optimized independently - the PCB bridge provides flexible electrical coupling to the LEDs while the PCB connector provides a standardized interface for external wire connections, maintaining both simplicity and mechanical flexibility.
Solution Approach 2:
The PCB bridge is designed as a flexible printed circuit board that can bend and conform to the housing structure. This flexibility allows the electrical connection to adapt to mechanical deformations of the 3D LED structure without compromising the electrical coupling, thereby maintaining mechanical flexibility while providing simple standardized connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable electrical connection of 3D LEDs to vehicle power sources without risking damage to the LED housing, ensuring mechanical flexibility and thermal stability, thus meeting the requirements of automotive lighting applications.
Implementation Method 1
The electrical contact is configured for electrical coupling with at least one interposer of a string of LEDs. The PCB connector comprises an electrical contact configured for electrical coupling with at least one external electrical wire.
Data Source
AI summary
An electrical contact, a 3D LED and a method of manufacturing 3D LEDs are described. The electrical contact includes a printed circuit board (PCB) bridge and a PCB connector. The PCB bridge comprises at least one electrical contact. The at least one electrical contact is configured for electrical coupling with at least one interposer of a string of LEDs. The PCB connector is electrically coupled to the PCB bridge. The PCB connector comprises an electrical contact configured for electrical coupling with at least one external electrical wire.